Blog Entries in manufacturing

Thursday, March 18th, 2010 - 11:16 am EDT

Automation Webinar Q&A

Posted by: Michelle Liro

Earlier this week, Craig Resnick, research analyst from ARC Advisory Group, joined us to discuss Best Practices for Preventing Downtime in Automation Systems. Craig's presentation was very well-recieved, with several attendees commenting on the high quality of the information Craig provided. If you haven't had a chance to see it yet, the on-demand recording is here and the recap of the Q&A from the webinar is below.

Q: Has the hierarchy at manufacturers changed where the groups that mange these different domains have converged, or are they still separate?
Craig Resnick, ARC Advisory Group: Over the last five years, we’ve seen the convergence of IT with the automation and operations groups. Five years ago we used to joke about the “civil wars” between these groups. IT used to poke fun at the factory floor about the age of the equipment, which can be 10, 20 or even 30 years old in some cases. The Factor Floor used to poke fun at IT because, as they put it, IT didn’t understand what “real-time” means. We’re finding now that there are many initiatives between these groups to converge different processes at different levels. This is an ongoing process that will take a while, but from what we’ve seen, once the convergence is made, it usually has very positive results for the business.

Q: Is everRun tested and approved by Siemens, Rockwell, etc.?
Yes. everRun works with a number of different automation systems and applications from Rockwell, Siemens, Johnson Controls, Dematic, Wonderware and many others. We’ve done qualification and certification testing with many vendors in the automation space. Because of the way that everRun is designed, it is almost transparent to the application, so we really can work with most vendors and have a very quick validation/certification process.

Q: Will a TCP connection from a SQL client to a SQL server be maintained through a failover?
At Marathon, we take a different approach to application availability. It’s not about failover and recovery, it’s about keeping systems up and running, even during a failure, with no impact to the users or the data. Failover isn’t something that we really do. We can actually maintain those connections, even with a failure, at all times if that’s what you need. We can maintain all connectivity, transparent to the user and the IP connections, and keep the system states intact.

Q: Does everRun work in both physical and virtual environments?
Yes, everRun works in both physical and virtual environments. We can protect both single and multiple workloads.

Q: What is the typical integration period to get everRun up and running at a site?
A typical engagement is about 2-3 days. The software itself installs very quickly and then after that there is the deployment and migration of applications, testing and training. WE provide these services through our everRun ONE program.

Q: What is the typical overhead of everRun?
That will vary based on the application. Anywhere from 5-15% depending on the characteristics of the applications – storage intensive, I/O intensive, etc. But 5-15% is a typical estimate.

Q: Are the partnerships validated in both physical and virtual environments? We use the Dematic voice picking application.
We do support Dematic applications in both physical and virtual environments. Some of our vendors have only tested physical, some virtual and some both. Our technology is very similar for both physical and virtual, and in most cases will work with most applications in both. If you have a specific application that you would like to check on, just give us a call.

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Webinar  Interview  Manufacturing  SQL  Virtualization 

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Tuesday, March 9th, 2010 - 10:52 am EST

Q&A with Craig Resnick of ARC Advisory Group

Posted by: Michelle Liro

Next week Craig Resnick, research director and automation expert at ARC Advisory Group will be the guest speaker for our webinar "Best Practices for Preventing Downtime in Automation Systems."  We recently sat down with Craig to discuss some of the recent trends in the manufacturing and automation industries.

Q: What are some of the newer trends that you are seeing in the automation space?

Craig Resnick: A primary trend that we see at ARC is the convergence of automation and IT systems. Nearly every manufacturing company uses a variety of plant automation and enterprise IT systems to manage its operations. Plant floor systems, such as distributed control systems (DCS), programmable automation and logic controllers (PACs/PLCs), and a wide range of plant floor applications provide a wealth of real-time information regarding productivity, efficiency, equipment health, capability, and quality. Business systems, in turn, provide information on raw material costs, product orders and inventories, manufacturing resources, production schedules, etc. This wide range of information often remains isolated in systems such as manufacturing execution systems (MES), laboratory systems, maintenance systems, scheduling systems, enterprise resource planning (ERP) systems, supply chain management (SCM) systems, and customer relationship management (CRM) systems. Decisions based on data from any one of these system will always be less than optimal because, without the corresponding information from the other systems, the information will be incomplete.

To close this gap between automation and IT systems, and to address the trend of the plant floor becoming more IT-centric, ARC has defined a new space, defined as Collaborative Production Systems. These new systems consist of platforms in which the controls layer domains of process, logic, motion, building automation, and power control systems converge with the information layer domains of production management and MES systems. These converged systems enable, for example, the required data and information to be directly tied into applications such as corporate reporting and manufacturing compliance. Collaborative Production Systems will become the industrial blade server that provides full monitoring and control of the enterprise, from the office to the plant floor, sharing that information with the supply chain to, for example, procure materials and resources and purchase or sell power at the optimal times and prices from the smart grid, while providing full financial metrics and KPIs to ERP systems to maximize profitability.


Q: Now that corporate reporting and systems are heavily tied into the “factory floor”, how is that changing the need for system availability and data protection?

Craig Resnick: The need for system availability and data protection continues to expand, driven by a combination of issues ranging from global competition to regulatory requirements. Process safety and critical control are primarily focused on system availability and process uptime. As a specific example, take the Pharmaceutical industry, where data and batch information can never be lost or interrupted. System availability and data protection needs are also forcing E-records regulations to evolve across the globe. In the US, this includes 21 CFR Part 11, as well as the FDA’s Good Manufacturing Practice (GMP) and Process Analytical Technology (PAT) initiatives. In Europe, this includes Annex 11 of the EU GMPs, electronic Signatures Directive 1999/93/EC, and Data Protection Directive 95/46/EC. The European Data Protection Directive requires even more protection on data than the current FDA regulations and extends this requirement to clinical trials patients, as all clinical trials data requires maximum protection to remain compliant with regulations.

Unscheduled downtime is expensive. It often impacts production’s ability to meet its schedule and may cause missed customer commitments. Unplanned downtime, which also includes unexpected stoppages resulting from equipment failure, operator error, or nuisance trips, is the nemesis of all manufacturers. Statistics on the impact of unplanned downtime on plant operations show that it accounts for 2 to 5 percent of production lost in, for example, the petrochemical industry. Unscheduled downtime is also costly in terms of equipment damage, environmental harm, and worker safety. The cost of downtime is reflected in a primary key performance indicator (KPI) used by manufacturers known as Dynamic Overall Equipment Effectiveness (OEE), which helps determine the real-time impact of the performance of any individual process or piece of equipment on the overall efficiency of the plant. Unscheduled downtime is a primary factor that significantly lowers Dynamic OEE, which translates to the manufacturer decreasing both its efficiency and profitability.

Q: What are some of the basic steps that companies can implement to ensure the availability of their systems?

Craig Resnick: The first step that companies can implement to ensure the availability of their systems is to maximize their operator’s effectiveness in the control room, which is essential to minimize the risks of accidents, eliminate unscheduled downtime, and maximize production quality. The global process industry loses $20 billion, or five percent of annual production, due to unscheduled downtime and poor quality. ARC estimates that almost 80 percent of these losses are preventable and 40 percent of those preventable losses are primarily the result of human or operator error. Maximizing operator effectiveness requires automating as many functions as technology will allow, as well as reducing complexity wherever possible. For example there are still many plants where operators monitor the processes and collect data manually or semi-automatically using chart recorders. This process is both tedious and error prone, and does not provide appropriate process insight or instill a sense of ownership among the control room operators.

The Abnormal Situation Management Consortium (ASM) points out that most incidences occur from multiple modes of failure. Preventable human error is a contributing factor to these losses, but is hardly the only cause. Preventing abnormal situations requires a multilayered multi-discipline approach focused on maximizing production throughput, efficiency and quality while minimizing lost production time and preventing damage to assets and endangerment to personnel. This approach requires deploying collaborative production systems designed and implemented to be able to deliver high levels of availability and fault-tolerance expected from any other mission critical industrial system. This typically requires effective data backup mechanisms, redundant controllers for critical applications, plus industrial grade software. Manufacturers are also deploying more fault tolerant server technology to ensure continuous availability of these mission critical applications; the continuous flow of vital products to the market; and the avoidance of the potentially negative financial, social, or environmental impact that operating without high availability fault-tolerant systems might bring.

 

To learn more about preventing downtime in your automation applications, be sure to attend next week's webinar where Craig will provide expert info on steps for reducing the human error that leads to downtime, how to protect your hardware, storage and networks for complete availability coverage, and how to protect against a complete site failure. You can register here.
 

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Manufacturing  Downtime  Fault Tolerance  High Availability  Interview  Webcast  Webinar 

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Tuesday, August 26th, 2008 - 11:54 am EDT

Vehicle Manufacturing Executives Talk About everRun

Posted by: Brian Mullins

In the vehicle manufacturing industry, companies want an efficient and economical way to ensure smooth operation of all servers, software and applications. Any instance of unscheduled downtime could lead to a loss of data, or in a worst case scenario, to a complete disruption of production and services.

Serve customer needs online without interruption

One European vehicle manufacturer, who understands the importance of protection against downtime, has been using Marathon solutions since 2000. As their security needs as an organization have grown, so has their relationship with Marathon. They began by using the Endurance 4000 system to help protect their forklift management system. Three years later, they upgraded to everRun FT to further safeguard files and applications and to ensure continuous server availability.

The implementation of everRun FT gave the company the opportunity to undertake other IT projects to maximize efficiency and reliability. They were able to establish a centralized network to allow the entire staff to access all applications and system updates remotely.

Defend 24/7 operations with Marathon everRun FT software

With these new initiatives in place, one company executive says that it is now more important than ever for applications and servers to be accessible 24/7 – no matter what. “A disruption to the provision of data and applications would affect every employee, and in the worst case scenario, halt operations altogether,” said the executive.

The company uses both Marathon’s everRun FT and SplitSite to allow two servers to operate simultaneously in 100 percent lock-step. SplitSite provides an additional layer of protection against larger scale failures and disasters. This means that the two servers create a single virtual environment and if one fails, no downtime will occur and all software, applications and data will continue to run on the remaining server.

The organization utilizes several levels of security, including a single server, a Windows cluster, and a Marathon System, but all of their most important and mission-critical applications are operated on everRun FT.

Elimination of system failure and increased competitive advantage

Any instance of unscheduled downtime would impact not only the company’s main factory, but also their several hundred other outlets. If an employee was unable to connect to the network because the server was down, all data on customers and products would become unavailable – this could mean a stall on productivity and unhappy customers. The company executive maintains that this is no longer a concern, thanks to Marathon. “With everRun FT, we no longer have to worry about downtime.”

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Availability  Case Study  Downtime  EverRun  Manufacturing  Marathon 

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